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Брестский государственный технический университет

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HPR 260 Manual Instrution

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APPENDIX A – CNC INTERFACE PROTOCOL

Status codes

ID	Name
00	IDLE
02	PURGE
03	IDLE2
04	PREFLOW
05	PILOT ARC
06	TRANSFER
07	RAMPUP
08	STEADY STATE
09	RAMPDOWN
10	FINAL RAMPDOWN
11	AUTO OFF
12	TEST CUTFLOW
14	SHUTDOWN
15	RESET
16	MAINTENANCE
20	TEST PREFLOW
22	MANUAL PUMP CONTROL
23	INLET LEAK CHECK
24	SYSTEM LEAK CHECK

Gas type codes

ID	Gas type
0	No gas
1	Oxygen
2	Methane (CH4) Not supported
3	H35 (Argon – Hydrogen)
4	H5 (Not supported)
5	Air
6	Nitrogen
7	CO2 (Not supported)
8	F5

a-18	HPR260 Auto Gas Instruction Manual

APPENDIX A – CNC INTERFACE PROTOCOL

CNC requirements

Below is a list of functionality that CNCs must offer for the automatic gas console version of the system. In this system configuration there is no local control of the plasma system. All settings and diagnostic information will be under CNC control.

1.Display and adjust the current setpoint – cutting current, see command ID#95

2.Display and adjust the plasma preflow setpoint – pressure setting, see command ID#95

3.Display and adjust the plasma cutflow setpoint – pressure setting, see command ID#95

4.Display and adjust the shield preflow setpoint – pressure setting, see command ID#95

5.Display and adjust the shield cutflow setpoint – pressure setting, see command ID#95

6.Display and adjust the plasma gas type – Inlet gas selection, see command ID#95

7.Display and adjust the shield gas type – Inlet gas selection, see command ID#95

8.Display and adjust the gas mixing setpoint – pressure setpoint, see command ID#95

9.Display the system error code – error code numbers, see command ID#3

10.Display the system status code – status code numbers, see command ID#2

11.Manual pump control – manually turn on/off the pump, see command ID#71

12.Display the firmware version – version of power supply and gas console firmware, see command ID#1

13.Test preflow gases – put the system in test gas mode, see command ID#64,65

14.Test cutflow gases – put the system in test gas mode, see command ID#66,67

15.Power On/Off – turn on/off the plasma system, not a serial command (active low, dry contact, opto-isolated)

16.Display line voltage – see command ID#100

17.Display chopper current(s) – see command ID#100

18.Display work lead current – see command ID#100

19.Display chopper temperature(s) – see command ID#100

20.Display transformer temperature – see command ID#100

21.Display gas pressures – see command ID#79

22.Display coolant flow rate – see command ID#100

HPR260 Auto Gas Instruction Manual

a-19

APPENDIX A – CNC INTERFACE PROTOCOL

Serial interface guidelines

Checksum

The protocol used for the serial interface between the Hypertherm system and the CNC contains a checksum on the message being sent. The checksum should be validated for all messages to ensure the information is not corrupted.

Message retries

We recommend retrying a message if the original message was not acknowledged by the system. This is especially important when the high frequency ignition is active. The high frequency ignition can be active for up to 1 second and can corrupt serial communications. It is important to space the retries so that the system can handle an interruption in serial communications for up to 1 second.

Another alternative to handling the high frequency ignition is to poll for the power supply state, using the GET_STATE command. If the state is (5 – Pilot arc) then stop serial communications until the state is no longer (5 – Pilot arc).

Cable shielding

We have chosen to use metal shell DB style machine/serial interface cables on some on the newer systems. One of the reasons this type of cable was selected is for their EMI shielding capabilities. It is important that integrity of the shielding of this cable is maintained. The shielding provides protection from the high frequency ignition system, if the cable shields are not properly terminated then the protection is not as effective. This is best achieved by ensuring the shield has a 360° termination provided on both end of the cables. Using a drain wire will not achieve the proper shielding. The cable should also be as short as possible with no coils.

Application Notes

Transmitting extra characters at the end of a message or transmitting while the plasma system is responding.

The original control board 041808 and power supply control software revision H and prior can sometimes “lock up” when the power supply is receiving characters while it is transmitting. The reason for this is that the control system cannot process interrupts fast enough. In some cases, when a receive and transmit interrupt occur very close together the system will miss one of the interrupts and will not process any more serial characters. Under normal conditions this will not be an issue. As long as you wait for a response to every command before transmitting the next command the problem will not occur. Also it is important not to include extra characters at the end of a command such as a carriage return or line feed. These are not required and can cause problems.

Power supply control software revision P improves the capability of the system and will reduce the likelihood of occurrence, however it can still happen. The new style control board 041909 has fixed the problem in hardware.

a-20	HPR260 Auto Gas Instruction Manual

Appendix B

BENZOTRIAZOLE / PROPYLENE GLYCOL SAFETY DATA

In this appendix:

Benzotriazole / Propylene Glycol Safety Data

Section 1	Chemical Product and Company Identification.......................................................................................	b-2
Section 2	Composition / Information on Ingredients ...............................................................................................	b-2
Section 3	Hazards Identification .............................................................................................................................	b-2
Section 4	First Aid Measures ..................................................................................................................................	b-3
Section 5	Fire Fighting Measures ...........................................................................................................................	b-3
Section 6 Accidental Release Measures ................................................................................................................		b-3
Section 7	Handling and Storage .............................................................................................................................	b-3
Section 8	Exposure Controls / Personal Protection................................................................................................	b-4
Section 9	Physical and Chemical Properties ..........................................................................................................	b-4
Section 10	Stability and Reactivity............................................................................................................................	b-4
Section 11 Toxicological Information.........................................................................................................................		b-4
Section 12	Ecological Information ............................................................................................................................	b-5
Section 13	Disposal Considerations .........................................................................................................................	b-5
Section 14 Transport Information..............................................................................................................................		b-5
Section 15	Regulatory Information ...........................................................................................................................	b-5
Section 16	Other Information....................................................................................................................................	b-5
Freezing point of Propylene Glycol solution .............................................................................................................		b-6

HPR260 Auto Gas Instruction Manual

b-1

MATERIAL SAFETY DATA SHEET

SECTION 1 – CHEMICAL PRODUCT AND COMPANY IDENTIFICATION

PRODUCT NAME		Hypertherm Torch Coolant


Latest Revision		09-02-2004
Date			EMERGENCY TELEPHONE NUMBERS

ISSUE DATE	03-10-2005
DISTRIBUTOR:		Hypertherm, Inc.	Transportation:	(800) 424-9300 *
STREET ADDRESS:		Etna Road	*For spill, leak, fire or transport accident emergencies.
CITY, STATE, ZIP:		Hanover, N.H. 03755	Product Information:	(603) 643-3441

SECTION 2 – COMPOSITION / INFORMATION ON INGREDIENTS

HAZARDOUS			EXPOSURE LIMITS
COMPONENT	CAS No.	% by wt.	OSHA PEL	ACGIH TLV	R PHRASES
Benzotriazole	95-14-7	<1.0	N.E.	N.E.	R22,36/37/38

Propylene Glycol	57-55-6	<50.0	N.E.	N.E.	R36/37/38

SECTION 3 – HAZARDS IDENTIFICATION

	EMERGENCY	Causes eye irritation.
	OVERVIEW	May be harmful if swallowed.
		May cause skin irritation


	POTENTIAL HEALTH EFFECTS

	INGESTION .......................................		Oral LD 50 (rat) as reported for 100% Benzotriazole is 560 mg./Kg.

	INHALATION .....................................		Mists are harmful.

	EYE CONTACT	.................................	Causes eye irritation.

	SKIN CONTACT ................................		Can cause skin irritaion.


b-2			HPR260 Auto Gas Instruction Manual

MSDS

PAGE 2 OF 4

PRODUCT

Hypertherm Torch Coolant

CODE

SECTION 4 – FIRST AID MEASURES

INGESTION

Never give anything by mouth to an unconscious person. Give several glasses of water. If

vomiting is not spontaneous, induce vomiting. Keep airway clear. Get medical attention.

INHALATION

If affected, remove from exposure. Restore breathing. Keep warm and quiet. Get medical

attention.

EYE CONTACT

Immediately flush eye with cool running water. Remove contact lenses if applicable.

Continue flushing with water for at least 15 minutes. Get immediate medical attention.

SKIN CONTACT

Wash with soap and water. If irritation develops or persists, get medical attention.

NOTE TO

Treatment based on judgment of the physician in response to reactions of the patient.

PHYSICIAN

SECTION 5 – FIRE FIGHTING MEASURES

FLASH POINT / METHOD

None to boiling.

FLAMMABLE

Not Established

LIMITS

EXTINGUISHING MEDIA

Product is an aqueous solution. Use Carbon Dioxide, Dry Chemical, Foam.

SPECIAL FIRE FIGHTING

Full protective equipment including self-contained breathing apparatus

PROCEDURES

should be used. During emergency conditions overexposure to

decomposition products may cause a health hazard. Symptoms may not be

immediately apparent. Get medical attention.

FIRE AND EXPLOSION

Water base solution.

HAZARDS

SECTION 6 – ACCIDENTAL RELEASE MEASURES

RESPONSE

Small spills: Mop up residues and place in a covered waste disposal container.

TO SPILLS

Large spills: Dike or dam spill. Pump to containers or soak up on inert absorbent. Place in

covered waste dissposal container.

SECTION 7 – HANDLING AND STORAGE

HANDLING

Keep container in upright position. Avoid breathing or creating airborne mists. Avoid

PRECAUTIONS

contact with skin eyes, and clothing. Avoid inhalation of vapor or mists. DO NOT TAKE

INTERNALLY. Clean up spills immediately.

STORAGE

Store in a cool dry place. Keep from freezing. Keep containers tightly closed when not

PRECAUTIONS

in use.

HPR260 Auto Gas Instruction Manual

b-3

MSDS

PRODUCT

Hypertherm Torch Coolant

CODE

PAGE 3 OF 4

SECTION 8 – EXPOSURE CONTROLS / PERSONAL PROTECTION

HYGIENIC PRACTICES

Normal procedures for good hygiene.

ENGINEERING CONTROLS

Good general ventilation. Eye wash station in immediate area of use.

M.E.L./O.E.S Nil.

U.K HSE EH:40 Not listed

PERSONAL PROTECTIVE EQUIPMENT

RESPIRATOR

If exposed to mists.

GOGGLES / FACE SHIELD

Recommended

APRON

GLOVES

Recommended; PVC, Neoprene or Nitrile acceptable

BOOTS

SECTION 9 – PHYSICAL AND CHEMICAL PROPERTIES

APPEARANCE

Clear Pink/Red Liquid

BOILING POINT

100EC

ODOR

None

FREEZING POINT

Not established

pH of Concentrate

5.5-7.0

VAPOR PRESSURE

Not applicable

SPECIFIC GRAVITY

1.0

VAPOR DENSITY

Not applicable

SOLUBILITY IN WATER

Complete

EVAPORATION RATE

Not determined

SECTION 10 – STABILITY AND REACTIVITY

CHEMICAL STABILITY

STABLE

UNSTABLE

CONDITIONS TO AVOID

None

INCOMPATIBILITY

None Known

HAZARDOUS PRODUCTS

BY FIRE: Carbon Dioxide, Carbon Monoxide Nitrogen Oxides

OF DECOMPOSITION

POLYMERIZATION

WILL NOT OCCUR

MAY OCCUR

CONDITIONS TO AVOID

Not applicable

SECTION 11 – TOXICOLOGICAL INFORMATION

CARCINOGENICITY

THIS PRODUCT CONTAINS A KNOWN OR SUSPECTED CARCINOGEN

XTHIS PRODUCT DOES NOT CONTAIN ANY KNOWN OR ANTICIPATED CARCINOGENS ACCORDING TO THE CRITERIA OF THE NTP ANNUAL REPORT ON CARCINOGENS AND OSHA 29 CFR 1910, Z

OTHER EFFECTS

ACUTE	Not determined
CHRONIC	Not determined

b-4	HPR260 Auto Gas Instruction Manual
0

MSDS

PRODUCT

Hypertherm Torch Coolant

CODE

PAGE 4 OF 4

SECTION 12 – ECOLOGICAL INFORMATION

BIODEGRADABILITY

CONSIDERED BIODEGRADABLE

NOT BIODEGRADABLE

BOD / COD VALUE

Not established

ECOTOXICITY

As reported for 100% Benzotriazole: Bluegill Sunfish (96 hr. Tlm):28mg/l; Minnow

(96hr. Tlm):28mg/l; Trout (96 hr. LC 50): 39mg/l; Algae(96hr. EC 50): 15.4mg/l;

Daphina magna (48 hr. LC 50): 141.6mg/l

SECTION 13 – DISPOSAL CONSIDERATIONS

WASTE DISPOSAL METHOD

Waste material must be disposed of in accordance with national/local

legislative requirements.

RCRA CLASSIFICATION

Non Hazardous

RECYCLE CONTAINER

YES

CODE

2 – HDPE

SECTION 14 – TRANSPORT INFORMATION

DOT CLASSIFICATION

HAZARDOUS

NOT HAZARDOUS

DESCRIPTION

Not applicable

SECTION 15 – REGULATORY INFORMATION

REGULATORY STATUS: Benzotriazole

1.	Labeling Information	Irritant
2.	R Phrases	R 36/37/38, 22
3.	S Phrases	S 24/25, 26
4.	EI NECS No.	Not listed
5.	EC annex 1 Classification	Nil.
6.	German WGK	—

SECTION 16 – OTHER INFORMATION

NFPA CLASSIFICATION

1	BLUE	HEALTH HAZARD
0	RED	FLAMMABILITY
0	YELLOW	REACTIVITY
—	WHITE	SPECIAL HAZARD

Information contained in this MSDS refers only to the specific material designated and does not relate to any process or use involving other materials. This information is based on data believed to be reliable, and the Product is intended to be used in a manner that is customary and reasonably foreseeable. Since actual use and handling are beyond our control, no warranty, express or implied, is made and no liability is assumed by Hypertherm, Inc., in connection with the use of this information.

HPR260 Auto Gas Instruction Manual	b-5
	0

Temperature, °F

0 -10 -20 -30 -40 -50 -60

-70
0	10	20	30	40	50	60

% of Propylene Glycol

Freezing Point of Propylene Glycol Solution

b-6	HPR260 Auto Gas Instruction Manual

Changed Page	Description	IM805000 Rev 0 to 1
		8/5/05
vi	Corrected page number for error code troubleshooting 8 of 8. It was 5-13. Changed to 5-14

vii	Hardware (a-3) removed from table of contents. There is no hardware header.

3.29	Updated art for step number 5 to show the new pilot arc connector. Added text to step number 5 "
3.29	Tighten by hand only".
	Tighten by hand only".

	Corrected recommended cable size for 200/208V, rated for 90 degrees C. It was (2 AWG) and is now
3.33	(2/0 AWG). Corrected recommended cable size for 240V, rated for 60 and 90 degrees C. 60 degrees
	C was (4 AWG) and is now (4/0 AWG). 90 degrees C was (1 AWG) and is now (1/0 AWG)

3.37	The screen shots were fuzzy and have been replaced with the higher resolution jpeg from page 3.36.

4.14-4.39	All marking cut charts updated.

5.7-7.14	Added Metric units where needed in the troubleshooting tables.
(General)
(General)

5.12	The description for error code number 102 was changed from "Chopper current signal is active on
5.12	power-up" to "No current or over-current detected during chopper test at power-up".


5.21	Removed "and strainer" from heading. There is no strainer in the cooling system.

5.40 and 5.41	Corrected the numbering of the checklist. It used to go from number 4 to number 6.

6.2 and 6.5	Added /208 to the description for part number 078187.

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